Transcript
Owner’s Manual Safety, Installation, Maintenance, and Operation
Model SHD-138/60P
American Eagle, Inc. 740 N. State Street PO Box 169 Garner, IA 50438 800-392-3015 Fax: 641-923-9099 www.americaneagleacc.com
Subject to Change without Notification. © 2012 American Eagle
Last Revision: 01/27/12
Introduction
American Eagle Compressors are designed to provide safe and dependable service for a variety of operations. With proper use and maintenance, American Eagle Compressors will operate at peak performance for many years.
necessary for product improvement or commercial/production purposes. This right is kept with no requirement or obligation for immediate mandatory updating of this manual.
This product manual is not intended as a training manual for beginners or unskilled operators. This manual offers guidelines for correct and safe usage of the compressor, maintenance, and troubleshooting. If more information is required or technical assistance is needed, please contact AE Technical Support.
This manual contains information vital to the safe use and efficient operation of this unit. Following the information provided within this manual can ensure the longevity of the compressor. Carefully read and study the operator’s manual before using the unit. Failure to adhere to the instructions could result in property damage or even serious bodily injury to the operator or others close to the compressor.
Some sections of this manual contain information pertaining to all American Eagle manufactured compressors and may or may not apply to your specific model.
A copy of this manual is provided with every compressor and shall remain with the compressor at all times. Information contained within this manual does not cover all maintenance, operating, or repair instructions pertinent to all possible situations. This manual is not binding. American Eagle reserves the right to change, at any time, any or all of the items, components, and parts deemed
If this manual becomes damaged, misplaced, or unreadable at any point, or if you feel that any part of this manual is unclear or incorrect, please contact AE Technical Support at 800321-3741 or email at
[email protected]
For Technical Questions, Information, Parts, or Warranty, Call Toll-Free at
800-321-3741
Hours: Monday - Friday, 8:00 a.m. - 5:00 p.m. CST Or email at the following addresses:
Technical Questions, and Information
[email protected]
Order Parts
[email protected]
Warranty Information
[email protected]
SHD-138/60P Manual 1
Table of Contents Safety
Page 3
Operation
Page 5
Specifications
Page 4
Head Unloading System Maintenance Installation
Page 6 Page 7 Page 8
Assembly Drawings
Page 12
Troubleshooting
Page 17
Replacement Parts
Page 16
Warranty
Page 19 SHD-138/60P Manual 2
Safety
This manual contains vital information for the safe use and efficient operation of this unit. Carefully read the operators manual before starting the unit. Failure to adhere to the instructions could result in serious bodily injury or property damage.
The SHD-138/60P Hydraulic Air Compressor will provide safe and dependable service if operated according to instructions. Read and understand the safety precautions given in this manual and on the decals attached to the shields. Failure to do so can result in personal injury or equipment damage.
all hose connections are tight, both air and hydraulic.
Establish a training program for all operators to ensure safe operation. Do not operate the compressor unless thoroughly trained or under the supervision of an instructor.
Operators and maintenance personnel must always comply with the safety precautions. These precautions are given here for your safety. Review them carefully before operating the compressor and before performing maintenance or repairs.
Do not operate the compressor if it is damaged, improperly adjusted or not completely or properly assembled. Never operate the compressor with any of the guards removed.
Supervising personnel should develop additional precautions relating to the specific work area and local safety regulations.
Do not attempt to adjust or disable the compressors air pressure relief valve. This valve limits the air pressure to 175 PSI.
Precautions Always wear safety equipment such as goggles, ear plugs and head protection at all times when operating the compressor.
The surface of the air compressor and the plumbing between the compressor and the cooler may reach temperatures above 150 degrees. Touching these surfaces during operation can cause burns.
Do not inspect or clean the compressor while the hydraulic power source is connected. Accidental engagement of the tool can cause serious injury.
The air taken in by the air compressor must be free of flammable fumes and vapors.
Before performing any maintenance on the compressor, place a warning tag on the hydraulic power source or disconnect the hoses from the compressor motor to prevent accidental startup of the compressor.
Compressor speed should not exceed 1000 RPM.
Use and operate this air compressor only in full compliance with all pertinent O.S.H.A. requirements and all Federal, State and Local codes or requirements.
Always connect hoses to the compressor before energizing the hydraulic power source. Be sure
SHD-138/60P Manual 3
Specifications
Drive System Description
• 16 GPM Hydraulic System
• 2000 PSI System Pressure
• Hydraulic Hose Plumbing
• 6061 Aluminum Manifold
• 2500 PSI Pressure Relief Setting
• 12 VDC Solenoid Control Valve
• Belt drive w/Gates 3B90 belt
• Air Pressure Control Valve
Compressor System Description
• Cast Iron Crankcase Casting
• Tapered Roller Main Bearings
• Precision Balanced Flywheel
• Pressure Relief Valves in Interstage and Discharge
• Gasket-free Integrated Cylinder/Head
• Heavy Ductile Iron Crankshaft
• Large Diameter Finned Inner Cooling Tubing • Positive Acting Centrifugal Head Unloaders
• • • • • • • •
• Pressure Lubricated System
• Preset Pilot Control Valve
General Information
Model: Weight: Delivery: Maximum Working Pressure: Electrical: Crankcase Oil Capacity: Cylinders: Maximum Compressor Speed:
Champion R40 800 lbs. (dry) 60 SCFM @ 175 PSI 175 PSI 12 VDC @ 10 amp 4 Quart Two Cylinder(Dual Stage) 1000 RPM
SHD-138/60P Manual 4
Operation
Each compressor is bench tested under load at the factory to ensure proper break-in and operation. While it is not necessary to follow any break-in procedure, the following checks should be made before putting the unit into service and periodically during use.
Before Start-Up
Inspect unit for any visible signs of damage.
Check the oil level in the compressor with the dipstick on the unit. If oil is needed, use American Eagle synthetic compressor oil (P/N C0087) or an equivalent synthetic oil. Note: There may be oil left in the crankcase from the factory bench test. Overfilling may cause the compressor to back blow oil. Always check the oil level and fill to the designated marking on the dipstick before putting the unit into service. Check hoses (air and hydraulic) for weak or worn condition and make sure that all connections are secure. Check the air intake filters on each head to make certain that they are clean and unobstructed. Dirty air filters are a possible cause of reduced air output.
General Information To use the compressor, start the vehicle engine and engage the hydraulic system. The compressor can now be activated using the compressor switch. This energizes the hydraulic solenoid sending oil to the hydraulic drive motor and starts the compressor. Through the air pressure switch and pilot valve, the system will now function automatically. Once engaged, adjust the engine speed control to ensure that the compressor speed does not exceed 1000 RPM under load. Adjustment instructions are provided with the speed control unit.
compressor to pump air. See head unloading system for detailed views and adjustment instructions the following page.
Operating Notes This reciprocating compressor must not be used for breathing air. To do so will cause serious injury whether air is supplied direct from the compressor source or to breathing tanks for later use. Any and all liabilities for damage or loss due to injuries, death and/or property damage, including consequential damages stemming from the use of this compressor to supply breathing air will be disclaimed by the manufacturer.
Air Pilot Valve Operation (Head Unloading System) When the hydraulic system is engaged the compressor will pump air into the receiver until the pressure reaches 175 psi. At this time the air pilot valve senses the pressure in the receiver and engages an intake valve hold-open mechanism. The compressor will run free until the pressure in the receiver falls below 145 psi and the air pressure valve disengages the intake valve hold-open mechanism to allow the
The use of this compressor as a booster pump and/or to compress a medium other than atmospheric air is strictly non-approved and can result in equipment damage and/or injury. Nonapproved uses will also void the warranty.
Never use plastic pipe or improperly rated metal pipe. Improper piping materials can burst and cause injury or property damage.
SHD-138/60P Manual 5
Head Unloading System
3/16" WHEN PISTON IS UP
CAUTION
When re-installing head unloader the actuating claw (Ref. No. 6) protrudes 3/16” below the bottom of the manifold (Ref. No. 1) as shown. Claw must be position so that it will enter three slots in the compressor valve. Failure to follow this procedure will result in an inoperative head unloader. ITEM 1 1A 2 3 4 5 5A 6 6A 7 7A 8
PART 26804 26807 7481 26812 7483 13924 13925 4567 13921 13922 13923 1056
DESCRIPTION LOW PRESSURE INTAKE MANIFOLD R70 HIGH PRESSURE INTAKE MANIFOLD R70 CYLINDER UNLOADER VALVE R70 UNLOADER PISTON R70 O'RING UNLOADER VALVE R70 PISTON ROD LP UNLOADER VALVE R70 PISTON ROD HP UNLOADER VALVE R70 CLAW UNLOADER VALVE LP R70 CLAW UNLOADER VALVE HP R70 SPRING UNLOADER VALVE LP R70 SPRING UNLOADER VALVE HP R70 NUT 0.25-28 HH
Air Pilot Valve Adjustment
QTY. 2 2 4 4 4 2 2 2 2 2 2 8
ITEM 9 10 11 12 13 14 15 16 17 18 19 20
PART 0521 7493 26821 26822 26823 7475 7498 C5568 26824 C6064 13735 13736
DESCRIPTION WASHER 0.25 LOCK GASKET UNLOADER VALVE R70 ACTUATING TUBE R70 MANIFOLD TUBE RB/LB R70 INTERMEDIATE TUBE R70 TUBE FTG R70 CPRSN TEE R70 UNLOADER VALVE CONRADER COMPRESSION FITTING R70 U BOLT 0.25X1.25X2.25 UNLOADER VALVE ASM LP R70 UNLOADER VALVE ASM HP R70
QTY. 12 2 1 1 1 2 3 1 1 1 2 2
(See Air Pilot Valve Adjustment Detail) High Pressure Adjustment: Proceed with the following while the compressor is running. 1.) Loosen locknut (4) and back off several turns. Do not turn differential adjuster (3).
2.) Check reading on the tank pressure gauge. Set the compressor maximum pressure at 175 psi. Over pressurizing compressor will cause damage and void warranty. Turn threaded cap (1) clockwise to increase pressure or counterclockwise to decrease pressure.
1.) Loosen locknut (2) and back off several turns.
2.) Check reading on the tank pressure gauge. Set the pressure to 30 psi differential (unload at 175 psi, reload at 145 psi). Turn nut (3) clockwise to increase differential pressure or counterclockwise to decrease differential pressure.
3.) After pressure is set, tighten locknut
4.) Be careful not to move the threaded cap (1).
3.) After pressure is set, tighten locknut (2). Be careful not to move nut (3)
Differential Pressure Adjustment: Proceed with the following while the compressor is running.
SHD-138/60P Manual 6
Maintenance
The following table is a list of routine maintenance items, including service intervals. Service intervals are listed as hours, days, or weeks, whichever occurs first. American Eagle recommends that these service intervals be followed. Before performing any maintenance function “Lock Out” or “Tag Out” all sources of power. Be sure all air pressure in unit is relieved. Failure to do so may result in injury or equipment damage. Maintenance operation
Service Intervals Daily
Drain air tanks
Weekly
Monthly
Hourly
Check crankcase oil level
Check fittings and airlines
Check hydraulic fluid level
Inspect and clean air intake filters Clean and operate safety valves Clean cooling fins on radiator Inspect check valve
Inspect and clean compressor valves
6
Replace air filters
3
6
Replace hydraulic filter
3
Tighten all fittings and fasteners
3
Check all electrical connections
Inspect and clean air check valve
CHANGE CRANKCASE OIL (see footnote below)
250
Under normal operating conditions, oil changes are required every 3 months. When operating in a dirty environment, change the oil more frequently as your particular operating condition dictates. USE AE SYNTHETIC COMPRESSOR OIL P/N C0087. COMPRESSOR CRANKCASE CAPACITY IS 5 QUARTS.
General preventative maintenance includes maintaining proper fluid level in both systems and the general cleanliness of the equipment. Proper fluids according to the specifications are required. SHD-138/60P Manual 7
Installation
COMPONENT INSTALLATION
This section pertains to the installation of the air compressor, PTO, pump and other related items. The instructions are intended as a guide to assist you with particular installation. These instructions will provide only general information.
Pump Assembly: The pump assembly may either be installed directly on the PTO or as an optional method, may be driven by a driveline from the PTO. Pump manufacturers provide specific installation information for their products and should be consulted if questions arise.
a toggle switch in a convenient location. Connect one terminal to the compressor pressure switch and the other terminal to a 12volt power supply. Add a 20 amp fuse between the battery and switch. A third wire is required from the air compressor pressure switch when connecting the speed control into the system. (See drawing below)
PTO Assembly: Check with the PTO manufactures representative for specific instructions regarding your particular make, model, and year of vehicle. As some trucks may require modification of the transmission cross member and the exhaust system, the manufacturer’s instructions should be followed to insure proper installation of the PTO.
Electric speed control: An optional electric or electronic speed control must be used to maintain proper operating speed of the air compressor. The engine speed control will automatically increase from idle to a preset speed when engaged and decrease when disengaged. The electric speed control (American Eagle P/N C0873) is used on most gasoline engines. The electronic speed controls are used only on Ford 6.0 and 7.3L diesel engines. Proper installation instructions are provided with each system.
Compressor Assembly: Prepare the mounting location of the compressor by locating and drilling four (4) holes, 9/16” diameter as per the mounting pattern of the air compressor base. Using four (4) 1/2” x 1.50 GR-5 cap screws,1/2” flat washer, and 1/2” nyloc nut, secure the compressor in place. The compressor is air cooled, and must have a clean supply of cooling air to the fan with minimum restrictions. Adequate space must be provided for proper circulation of air. Electrical Connections: From the solenoid valve (located on the hydraulic manifold) there are two (2) wires, red and black, running to the compressor pressure switch. Connect the black wire to the vehicle frame or other suitable ground. The red wire mounts to the pressure switch as shown. Install
SHD-138/60P Manual 8
Component Installation Continued... 3/4" HIGH PRESSURE HYDRAULIC HOSE LENGTH AS REQUIRED MOTOR CASE DRAIN ROUTED TO HYDRAULIC RESERVOIR
3/4" RETURN LINE TO RESERVOIR
Hydraulic System: Installed on the compressor is a valve block assembly that controls the flow to the hydraulic motor. To this block, a 3/4” high-pressure hose and a 3/4” return line must be attached. (See drawing above) Note: The case drain line from the hydraulic motor is also routed to the oil reservoir. American Eagle recommends a sufficient sized reservoir be provided which includes the proper suction and return filters. The cooler on the compressor is designed and sized to cool the air compressor efficiently. An auxillary oil cooler is required when additional hydraulically operated equipment are added to the hydraulic system. Pressure on the return line exceeding 200 PSI can and will cause damage to the filter, cooler, and components of the compressor hydraulic system.
SEE DETAIL A
SEE DETAIL B
NO C NC
DETAIL A
1/4" HOSE
DETAIL B CHECK VALVE MUST BE PLACED BETWEEN AIR DELIVERY LINE AND TANK
Air System: Two (2) airlines must be routed to the air tank for proper installation. The main airline is routed from the check valve to the air tank using a 3/4”(200psi) air hose. This is the main delivery line and should be free from all obstructions. A 1/4” line is routed from the air pressure valve to the air tank. This line senses the pressure in the tank and will engage and disengage the compressor automatically.
AIR SENSE LINE TO AIR TANK
SHD-138/60P Manual 9
Typical Hydraulic Circuit for Single Stage Pump with PN 30533 Multiple Components
Typical Hydraulic Circuit for Tandum (Two Part) Pump with PN 30532 Multiple Components
SHD-138/60P Manual 10
Typical Hydraulic Circuit for Compressor with Auxiliary Cooler
HYDRAULIC RESERVOIR
FILTER FILTER SCREEN
AUXILIARY COOLER
SUCTION PORT
SINGLE HYDRAULIC PUMP
COMPRESSOR
RETURN
PRESSURE
SHD-138/60P Manual 11
Assembly Drawings Compressor Assembly
Notes: 1. Hydraulic hose (PN C5480) from motor discharge to manifold is not shown. 2. Compressor oil drain hose (C0562) is not shown.
40
41 14
38
27
39 44 42 17 16 24 43
15
11 8 26
33
4
10
18 19 31 20
1 30
36
28
9
5
5 7
13
29
5
6
2 22 5
5
23 21
ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
PART 10642PC B0179PC 10093 C6106 D0790 0501 20456 C3075 C4913 C4914 C6015 C5549 C6188 9256 4703 8277 C0864 20330 C5662 C2274 B0843PC 8697
5
6
3
4 35 37
5
34 32
4
DESCRIPTION BASE WLDMT R40/R70 TOP MT BRKT HYD MOTOR MOUNT CPRSR MOTOR HYD M330A842VREB10-43 NUT 0.50-13 HHGR5 NYLOC WASHER 0.50 FLAT GR8 CAP SCR 0.50-13X2.00 HHGR5 NIPPLE 0.38X4.00 BRASS BLOCK AL CPRSR SHD 66 VALVE SOLND VALVE RELIEF CP-200-1-B-0-A-C FTG 0.75 PLUG 12-P5ON FTG ORB/JIC STRT CONNT 12-F5OX-S BUSHING 1.00 BELT 3B90 GATES (DAYCO RBP90-3) BRKT UNLOADER VALVE MNT SHD66DD FTG ST L 0.25 MNPT/0.125 FNPT SPL SWITCH PRES HOBBS FTG 0.38-0.25 FF HEX NIPPLE FILTER METAL BOWL 0.25 FTG HOSE BARB .25 HOSE X .25 MNPT ANGLE TIGHTENER CPRSR WLDMT CAP SCR 0.50-13X6.00 ALL THREAD GR5
ITEM 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
QTY. 1 1 1 12 26 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2
PART 0537 3853 C6064 C5968 28007 0359 20452 2772 5418 C0484 C4227 C6071 C2275 D1303 C5908 20884 5480 D1273 D1869 D0847 C1088 C4941
SHD-138/60P Manual 12
DESCRIPTION NUT 0.50-13 HH VALVE PILOT 145/175 PSI RCL-S U BOLT 0.25X1.25X2.25 FTG ADAPT 90 12-C5OLO-S COVER KIT SHD-245 CAP SCR 0.50-13X1.50 HHGR5 ELBOW 0.38 90 DEG BRASS CAP 8FNL-S ST EL 0.25 90 DEG BRASS 44-161 FTG #12 O'RING 0.75 BARB 90 FTG MF/MSTR 90 8-12 C5OLO-S HOSE CLAMP 0.75 FTG HOSE BARB .38 HOSE X .25 MNPT PULLEY SHEAVE 3 GROOVE 3B 94SK FTG 0.25 ML ELL NIPPLE 0.75X4.00 BRASS VALVE CHECK 0.75 STANDARD FTG 1.00-0.75 BUSH RED BRASS FTG 0.75-45 DEG ELBOW BRASS BRKT 11.00 TWIST 45 DEG SHD66DD CPRSR CHMP R40A-HU CLAMP MUFFLER 1 1/8
QTY. 2 1 1 1 1 4 1 1 1 2 1 2 1 1 1 1 1 1 1 2 1 1
R40 Breakdown Assembly
SHD-138/60P Manual 13
R40 Breakdown Parts List
Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
Description
C r a nk c a s e P ipe plug O il le ve l ga uge P ipe nipple P ipe c a p P ipe plug O il s e a l F lywhe e l K ey F lywhe e l wa s he r H e x he a d c a p s c r e w Governor housing gasket set (includes items 13, 14, 15 & 16) G a s k e t, . 0 3 1 ” thic k G a s k e t, . 0 1 5 ” thic k G a s k e t, . 0 1 0 ” thic k G a s k e t, . 0 0 6 ” thic k G ove rnor hous ing H e x he a d c a p s c r e w G ove rnor hous ing c ove r ga s k e t B a ffle pla te G ove rnor we ight G ove rnor we ight s pindle G ove rnor we ight pin L oc k wa s he r H e x he a d c a p s c r e w F la t wa s he r Ma in gove rnor s pring G ove rnor s pring s le e ve G ove rnor hous ing c ove r U nloa de r muffle r a s s e mbly H e x he a d ma c hine s c re w R e le a s e va lve plunge r R e le a s e va lve ba ll R e le a s e va lve s pring R e le a s e va lve c a p C ra nk s ha ft Ma in be a ring Connecting rod assembly (includes items 43, 44, 45 & 46) O il dippe r C onne c ting rod bolt C onne c ting rod nut P is ton pin be a ring L ow pre s s ure pis ton with pin L ow pre s s ure pis ton ring s e t L ow pre s s ure pis ton pin P is ton pin re ta ining ring H igh pre s s ure pis ton with pin H igh pre s s ure pis ton pin H igh pre s s ure pis ton ring s e t C ylinde r fla nge ga s k e t SHD-138/60P Manual 14
Part Number M1 4 5 3 64AA5 R E 714 M4 9 2 M4 6 1 64A5 P 03433A P 05723C M1 5 0 6 M1 3 9 4 M2 2 6 5 Z775 M1 3 9 8 M1 3 9 9 M1 4 0 0 M1 4 0 1 P 12274C M2 3 4 5 S E 1489 P 12381A S E 582B S E 583B S E 592A M3 4 6 8 M2 3 4 5 M9 1 2 A S E 590 S E 587 R E 10100A Z 4593 M3 4 7 3 S E 586B P 07841A S E 591 N R 101 M1 4 5 8 Z 6506 Z658 P 03440A P 03458A P 03459A P 03430A Z M1 9 06 Z 9087 M1 3 9 5 P 03434A Z M1 3 93 M1 3 8 3 Z 9088 M1 3 9 1
Qty. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 6 1 1 2 1 2 1 1 1 1 1 1 1 6 1 1 1 1 1 1 2 2 4 4 2 1 1 1 4 1 1 1 1
Ref. No.
R40 Breakdown Parts List Description
5 1 C ylinde r * 5 2 H igh pre s s ure inta k e ma nifold 5 3 L ow pre s s ure dis c ha rge ma nifold 54 High pressure discharge manifold (Non-Base Mount Units) 54 High pressure discharge manifold (Base Mount Units) * 5 5 L ow pre s s ure inta k e ma nifold 5 6 F e rule 5 7 C ompre s s ion nut 5 8 I nte rs ta ge pre s s ure re lie f va lve 5 9 D is c ha rge pre s s ure re lie f va lve 6 0 H igh pre s s ure va lve ga s k e t 6 1 H igh pre s s ure inta k e va lve a s s e mbly 6 2 L ow pre s s ure va lve ga s k e t 6 3 L ow pre s s ure dis c ha rge va lve a s s e mbly 6 4 L ow pre s s ure inta k e va lve a s s e mbly 6 5 R e le a s e va lve k it ( inc lude s ite ms 3 2 , 3 3 , 3 4 , & 3 5 ) 6 6 H igh pre s s ure dis c ha rge va lve a s s e mbly 6 7 H e x he a d c a p s c r e w 6 8 H e x he a d c a p s c r e w 6 9 I nta k e filte r 7 0 I nta k e filte r e le me nt 7 1 9 0 ° E lbow
Complete compressor pump gasket set (items 12, 19 & 50) L ow pre s s ure pis ton k it ( ite ms 4 3 , 4 4 , 4 5 & 4 6 ) H igh pre s s ure pis ton k it ( ite ms 4 6 , 4 7 , 4 8 & 4 9 ) C omple te c ompre s s or pump ring s e t ( ite ms 4 4 & 4 9 ) Valve set with gaskets (items 60, 61, 62, 63, 64, & 66) V a lve ga s k e t k it ( ite ms 6 0 & 6 2 ) *
Intake manifolds shown for Start-Stop units
Part Number
Qty.
P 05863D M1 4 3 1 M1 4 2 3 M1508 P05748A P 09711D P 06064A M1 4 1 8 M3 6 8 5 P 09704A P 07353A Z 784 P 07352A Z 274 Z 273 Z 12414A Z 785 M3 4 6 1 P 04779A P 07447A P 05051A M3 0 8 8
1 11 1 1 1 1 3 3 1 1 4 1 3 1 1 1 1 6 8 1 1 1
Z10888 Z 9108 Z 9107 Z 9109 Z656 Z 657
1 1 1 1 1 1
only. See page 26 for Head Unloader manifolds.
SHD-138/60P Manual 15
Replacement Parts
SHD138 Compressor - Replacement Parts Hydraulic Components/Drive Parts C4914 C4913 10093 C6188 D1303 9256 C3075 C6225
Relief Valve Solenoid Valve Hydraulic Motor Bushing 1.00" Pulley Sheave Pulley Belt 3B90 Gates Aluminum Manifold Block Hydraulic Oil Filter
Electrical/Air Pressure Components C0864 3853 C5662
Pressure Switch (Hobbs) Pilot Valve 145/175 PSI Filter Metal Bowl
Air Filter Components/Service Kits 26803 4562 62133
Filter Assembly R40 Filter Element (only) SHD138 Service Kit
Champion Compressor Components C1088
Compressor R40
Centrifugal Unloader Components C0896 7417
Release Valve Assembly Kit Muffler Assembly Unloader
Manifold/Valve Components 13731 13732 13733 13734 4563 4564 C1183
Valve Assembly (Low Pressure Intake) Valve Assembly (Low Pressure Exhaust) Valve Assembly (High Pressure Intake) Valve Assembly (High Pressure Exhaust) Complete Valve Gasket Set Complete Valve Set W/Gaskets Pressure Relief Valve SHD-138/60P Manual 16
Troubleshooting
If symptoms of poor performance develop, the following chart can be used as a guide to investigate and correct the problem. When diagnosing faults in operations of the air compressor, always check that the hydraulic power source is supplying the correct hydraulic flow and pressure that is listed in the compressor specification section of this manual. Problem
Compressor will not start:
Possible Cause
Solution
Emergency brake off.
Fully engage parking brake.
Engage PTO.
PTO not engaged. Blown fuse.
Loose or broken power/ground wire.
Compressor runs slow or slows down during operation:
Loose air lines or hoses.
Tighten air lines and hose connections.
Hydraulic motor worn.
Replace with new motor.
Check and reset flow.
Hydraulic flow too low.
Readjust relief valve. Clean or replace.
Faulty compressor valves. Pilot valve leaking air.
Centrifugal unloader valve leaking.
Replace pilot valve.
Remove the governor release valve cap, giving access to the unloader pressure release valve spring and ball - Clean thoroughly and reassembly. Hydraulic fluid low. Hydraulic reservoir size incorrect.
Hydraulic oil temp high.
Compressor runs hot:
Repair connection.
Compressor manifold solenoid will not Repair wiring to coil. Replace valve. engage.
Hydraulic relief set too low.
Compressor will lock up after operating for a short period:
Replace fuse.
Hydraulic motor drive coupler loose.
Reposition and tighten coupler.
Faulty check valve.
Clean or replace check valve.
Faulty hydraulic relief valve.
Remove relief valve, inspect o-rings and backup seals or replace relief valve.
Dirty after cooler or intercooler tubing. Remove and clean. Faulty compressor values.
Clean or replace valves.
Low crankcase oil level.
Add compressor oil as needed.
Clean or replace.
Dirty intake muffler.
SHD-138/60P Manual 17
Problem
Compressor will not shut down:
Possible Cause
Solution
Misadjustment of pilot valve.
Adjust valve per manual specifications.
Air line or air hose leaks. Pilot valve leaking air
Centrifugal unloader valve is leaking. Moisture or rust contamination.
Tighten air lines or hose connections. Clean or replace pilot valve.
See “Compressor runs slowly” section.
Remove filter bowl. Fill with WD40 lubricant. Open air tank valve. Run compressor for 10 minutes. Partially close air tank valve and cycle compressor. Repeat as needed.
Compressor continues to build air during idle mode:
Faulty low pressure intake valve.
Compressor will not speed up when compressor is activated:
Air reservoir full.
Drain air from reservoir.
No 12 volt power to coil solenoid valve located on hydraulic manifold.
Check fuse. Check ground wires. Check chassis emergency brake switch.
Engine RPM will not increase when compressor is activated:
Leaking or misadjustment of the pilot valve. Faulty pressure switch.
Loose wiring.
Tighten or adjust valve per manual specs.
Test for 12 volt power on both the “C” and “NC” side of the terminals. If no power on “NC” side of pressure switch, replace switch.
Check wiring to : Solenoid valve, pressure switch, ground wiring. Replace pressure switch.
Faulty pressure switch.
Check speed control wiring for loose or broken connections. Check relay (For ECM operated speed settings.)
Faulty speed control. Compressor cycles or runs often:
Clean or replace low pressure intake valves.
Faulty pressure switch.
Excessive water in air reservoir. Pip lines leaking air.
Misadjustment of pilot valve. Air leaking from pilot valve. Check valve leaking.
Replace pressure switch. Drain air reservoir.
Tighten or replace lines.
Adjust valve per manual specifications. Clean, adjust, or replace. Clean or replace.
Faulty pressure switch. Chassis engine RPM continue to operate at high Pressure switch wiring. speed when air receiver reaches maximum capacity:
Replace pressure switch.
Wires place on pressure switch incorrectly or loose ground wire.
SHD-138/60P Manual 18
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